(2001) berlingo c15 jumper jumpy

8/12/2019 (2001) Berlingo c15 Jumper Jumpy

1/344

UTILITY VEHICLES

CAR 050009

The technical information contained in this document is intended for the exclusive use of the trained person-nel of the motor vehicle repair trade. In some instances, this information could concern the security and safe-ty of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intendedand they alone would assume full responsibility to the exclusion of that of the manufacturer.The technical information appearing in this brochure is subject to updating as the characteristics of eachmodel in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically forfurther information and to obtain any possible updates.


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PRESENTATION

THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITRwhich there exists a separate handbook.

The handbook is divided into nine sections representing the main functions :

GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSSYSTEMS - ELECTRICAL - AIR CONDITIONING.

In each section, the various vehicles are dealt with in the following order: C15 - BERLINGO - BERLmodels where applicable.

This handbook applies only to vehicles in Europe.


3/344

IMPORTANT

If you find that this handbook does not always meet your requirements, we invite you tointo account when preparing future publications. For example :

# INSUFFICIENT INFORMATION

# SUPERFLUOUS INFORMATION

# NEED FOR MORE DETAILS

Please send your comments and suggestions to :

CITRON VK Ltd221 Bath Road

SLOUGHSLI 4 BA


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LPG safety recommendations 155 to 161DELPHI checking, timing 168 to 178BOSCH checking, timing 179 to 200IGNITION

Sparking plugs 201

CLUTCH-GEARBOX-TRANSMISSION

Speedometer 202Clutch, checking/adjusting 206 to 211Driveshafts 245

AXLES-SUSPENSION-STEERING

C15 246 to 248BERLING0 253 to 257DISPATCH 267 to 269RELAY 275

BRAKES

C15 281

BERLINGO 286 to 287DISPATCH 294 to 295RELAY 299 to 300

C15Handbrake 284Bleed of brakes 285

INDEX

GENERAL

C15 1 to 2BERLINGO 3 to 12DISPATCH 13 to 17RELAY 4x2 18 to 37RELAY 4x4 38 to 44

C15 46BERLINGO 47DISPATCH-RELAY 48 to 49

Lubricants 50 to 64

ENGINE

Specifications 65 to 67Cyl. head marking and 72 to 85Auxiliary equipment drive 86 to 112Checking the valve timing 113Valve clearances 145

Oil pressure checks 146Oil filters 149INJECTION

Petrol injection 151 to 152Idling, anti-pollution 153 to 154

Identificationof

vehicles

Capacities

Axlegeometry

Brakespecifications


5/344

IDENTIFICATION OF VEHICLES


6/344

GENERAL

IDENTIFICATION OF VC15 All Types

Version (1) (2) (3)

Payload (kg) 600 765

Emission standard W3

Type approval no. VD PB VD PP VD SX VD WT

Engine type 161 A

Cubic capacity (cc) 1769

Fiscal rating (hp) 7

Gearbox type BE3/5

Gearbox ident. 20 TE 11 (*

1.8 D

(1) Standard van

(2) Deepened cab

(3) Familiale

(*) = Strengthened gearbox.


7/344



8/344

GENERAL

W3 W4

MA HDZF MB HDZF MA HFXB

HDZ HFX

1124

6

MA/5

20 CD 42 # 09/2000

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Payload (kg)

IDENTIFICATION OFBERLINGO All Types

Petrol

1.1 i

A AB600475 475


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600 800 600

K' W3 W4

MB KFXG MB KFXF MC KFXF MB KFWB

KFX KFW

1360

8

MA/5

20 CD 74#

09/2000 20 C

IDENTIFICATION OF VEHICLESPetrol

1.4 i

B

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Payload (kg)


10/344

GENERAL

W3

MB WJZC MB WJZF MC WJZF

WJZ

1868

7

BE3/5

20 TE 22 20 TE 20

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Payload (kg)


Diesel

1.9 D

A B

600 800


11/344

IDENTIFICATION OF VEHICLESDiesel

B

Emission standardType approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Payload (kg) 600 800

W3MB RHYF MC RHYF M

RHY

1997

6

BE3/5

20 TE 27


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GENERAL

600

W3 W4 W3 W4

MA HDZV MA HFXB MB WJZF MB WJYB

HDZ HFX WJZ WJY

1124 1868

6 7

MA/5 BE3/5

20 CN 01 20 TE 20 20 TE 49

BERLINGO All Types IDENTIFICATION OFPostvan version

DieselPetrol

1.1i 1.9 D

A B

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Payload (kg)


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Floor cab

800

W3 W4 W3 W4

ME KFXF ME KFXB ME WJZF ME WJ

KFX KFW WJZ WJY

1360 1868

7

MA/5

20 CN 14 20 TE 20 20 TE

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Payload (kg)

Version


Petrol

1.9 D1.4i

B


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15/344

L4/W4 L3

MF KFWB/A MF KFXF/MOD GL MF KFXF/MOD GL

KFW KFX

1360

6

MA/5

20 CN 13 20 CN 12 20 CN 13

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


Petrol

1.4 i

Dual fuel

MultispaceXMultispace


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GENERAL

Emission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

L3/W3 L4/W4

MF WJZF MF WJZF/A MF WJYB MF WJYB/A MF

WJZ WJY

1868

5

BE3/5

20 TE 22 20 TE 24 20 TE 49 20 TE 24 20


Diesel

1.9 D

X-SX Multispace X-SX Multispace


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1

2

3

4

5

6

7

E1AP07BD


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GENERAL

(*) = Fiscal incentive L5 (EURO 4)

VersionEmission standard

Type approval no.

Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

(1) (2)-(3) (4)IF L5 (*)

BA RFNC/IF BZ RFNC/IF BA RFNC/IF

RFN

1997

BE4/5

20 DL 26 20 DL 27

IDENTIFICATION OF DISPATCH All Types

Petrol

2.0i 16V

A

Confort

(1) = Mixed van (short).(2) = Panel van (short).(3) = Glazed van (short).

(4) = Combi (5) = Combi (6) = Floor c


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(1)-(4) (2) (3) (7)-(8)

W3BA WJZA BZ WJZA BT WJZA

WJZ

1868

7

BE4/5

20 DL 33 20 DL 34

IDENTIFICATION OF VEHICLESDiesel

1.9 D

StandardConfort Confort


Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Version

(1) = Mixed van (short). (6) = Floor cab.(2) = Panel van (short). (7) = Panel van (long).(3) = Glazed van (short). (8) = Glazed van (long).(4) = Combi 5-seater (9) = Floor cab (long).(5) = Combi 9-seater


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GENERAL

(1)-(4) (2) (2)-(3) (7)-(8)

W3BA RHXA (*) BZ RHXA BY RHXA BS RHXA

RHX

1997

8

ML/5

20 LE 93

DISPATCH All Types IDENTIFICATION OF Diesel

2.0 HDi

Confort


Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Version

(1) = Mixed van (short). (6) = Floor cab.(2) = Panel van (short). (7) = Panel van (long).(3) = Glazed van (short). (8) = Glazed van (long).(4) = Combi 5-seater (9) = Floor cab (long).(5) = Combi 9-seater


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(*) = With DVA (Double damped flywheel)

(1) = Mixed van (short).(4) = Combi 5-seater(5) = Combi 9-seater

(1) (4)

L3BA RHZA

RHZ

1997

7

ML/5

20 LE 91 (*)


Engine type

Cubic capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

Version


Diesel

2.0 HDi


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GENERAL

5 Vehicle identification N.

6 Bodyshell N.

SPECIFICATIONS - IDEN

Identification

1 Gearbox identification reference.

2 Manufacturers name plate

3 Engine plate

4 Paint code

1 VIN N

2 Gross

3 Gross

4 Max.

5 Max. E1-P02UD

RELAY 4 X 2 All Types


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ENGINE

1

23458BCH

XU102CU

XU10J2UXUD9AUDJ5TEDDJ5XUD9UTF2.8D (*)2.8 TD (*)2.0HDi (*)

WHEELBASE

1

234

Short (2.85m)

Medium (3.20m)Long (3.70m)Superlong (4.05m)

BODY

A

BCDEFGHJKLNUV

TR

2

4

FAMILY

23

SPECIFICATIONS - IDENTIFICATION ( 4 x 2 ) (continued)

Type approval no. (Example) 2 3 2 G 5 2 /

U 3 VAN 9 Q 10 Q

VAN 14 QCOMBI 10 QMINIBUS 18 QCHASSIS 10 QFLOOR 10 QCHASSIS 14 QPLATFORM 14 QVAN 18 QCHASSIS 18 QPLATFORM 18 QFLOOR 18 QPLATFORM 10 QCOMBI 14 Q

(*) = SOFIM engineNOTE : BODYWORK in A (VAN 9Q 10Q) 9Q = Van version Reduced Gross laden weightEXAMPLE : 232G52/2 = Bare chassis medium, 2.5 diesel engine, 5-speed gearbox.


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GENERAL

Wheelbase InteriorPa

height 9 Q 10 Q

1.56 m 25C/250C 27C/270C

Short : 2.85 m 1.88 m 25 CH/250CS 27CH/270C

2.11 m 27CS/270C

1.56 m 27M/270M

Medium : 3.20 m 1.88 m

2.11 m

1.56 mLong : 3.70 m

1.88 m

Super long : 4.05 m 1.56 m

RELAY 4 x 2 - All Types SPECIFICATIONS - IDENTIFICCommercial type


25/344

(1) (2) (3) (6)

27

C/CH M C M C/CH

231A22 232A22 231C22/D 231C22/D 232E22 231B22

W3 L3 W3

RFW

1998

10 11 10

ML/5

20 UE 02


2.0i

I) (1) Panel or glazed van(2) Combi club

(3) Combi confort(6) Chassis cab.

II 27 = 10Q31 = 14Q

I

II

III

Type approval no.

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


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GENERAL

(3) (6) (

31

C M C M L

231V22/D 232V22/D 231G22 232G22 233G22 233G

L3

RFW

1998

9

ML/5

20 UE 02

RELAY 4 x 2 All Types IDENTIFICATION O

2.0i

I) (3) Combi club(6) Chassis cab.

(7) Chassis double cab.(8) Platform cab.(9) Platform double cab.

II 31 = 1

I

II

III

Type approval no.

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


27/344

(10) (1) (4) (5)

31 35

M MH/MS LH MH LH

232F22 232J22 2333J22232J22/ 233B22/

(*) MODGNV MODGNV 233V22(**) (**)

W3

RFW

1998

10

ML/5 MG/5

20 UE 02 20 KM 69


2.0i

I) (1) Panel or glazed van.(4) Minibus.(5) Minibus 15-seater.(6) Chassis cab.(7) Chassis double cab.(8) Platform cab.(10) Floor cab.

II 31 = 14Q

35 = 18Q

I

II

III

Type approval no.

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


28/344

GENERAL

(8) (10)

35

L M L

233L22 232N22 233N22233N22/

MODGNV (*)

W3

RFW

1998

10

MG/5

20 KM 69

RELAY 4 x 2 All Types IDENTIFICATION

2.0i

I) (8) Platform cab.(10) Floor cab.

II 35 = 18Q

I

II

III

Type approval no.

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


29/344

(1) (2) (3)

25 27

C/CH M C M

231A32/C231A32 232A32 231C32/D 232C32/D 232E32(*)

W3 L3 W3

DJY

1905

6

ML/5

20 UE 02


1.9 D

I) (1) Panel or glazed van(2) Combi confort.

(3) Chassis cab.

II 25 = 9Q # (*) /C = V

27 = 10Q III (See Co

I

II

III

Type approval no.

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


30/344

GENERAL

(1) (2) (4) (

27 31 2

C/CH M C/CH M/MH C

231A82 232A82 231B82 232B82 231C82D 232C

W3 L3

DHX

1905

8

ML/5

20 UE 01


1.9 TD

II 27 = 131 = 1

I

II

III

III

III

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van(2) Combi confort.(3) Chassis cab.

(4) Combi club(8) Chassis double cab.


31/344

(5) (6) (7

27 31

C M L M/MH

231U82 231H82 232H82 233H82 233H52/1 232F82

W3DHX

1905

6 8

ML/5

20 UE 02


1.9 TD

I) (5) Platform cab.(6) Platform double cab.(7) Floor cab.

II 27 = 10Q31 = 14Q

I

II

III

Type approval no.

Version

Emission standardEngine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.


32/344

GENERAL

(1) (2) (1)

27

C/CH M C C/CH M/MH L

231A52 232A52 231C52/D 231B52 232B52 233

(6) (8) (6)27

C L XL

231E52 231U52 233G52 234G52 232G

W3 L3

T9A

2446

8

ML/5

20 UE 00


2.5 D

II 27 = 131 = 1

I

II

III

III

III

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van(2) Combi confort.(6) Chassis cab.

(7) Chassis double cab.(8) Platform cab.


33/344

(9) (10) (1

31

M L C M/MH L/LH L

232H52/1 233H52/1 231F52 232F52 233F52 233G52/2

W3T9A

2446

8

ML/5 MG/5

20 UE 00 20 KM 74


2.5 D

I) (9) Platform double cab.(10) Floor cab.(11) Bare chassis.

II 31 = 14Q

I

II

III

Type approval no.

Version


Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

RELAY 2 All T IDENTIFICATION O


34/344

GENERAL

(1) (3) (4) (5) (

35

C/CH MH/MS LH (*) - LH/LS LH M

231J52 232J52 233J52 233V52 232K22 233

(9) (10) (11)

35L M/MH L/LH XL

233L52/1 232N52 232N52 234G52/2

W3

T9A

2446

8

MG/5

20 KM 73

RELAY 4 x 2 All Types IDENTIFICATION O2.5 D

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van(3) Minibus.(4) Public transport 16-seater.

(5) Minibus 15-seater.(6) Chassis cab.(7) Chassis double cab.

(8) Platform cab.(9) Platform double cab.(10) Floor cab.(11) Bare chassis.



35/344

(1) (2) (1)

27

C/CH M C C/CH M/MH M

231A42 232A52 231C42/D 231B42 232B42 232B42

(3) (7) (9) (7)

27C C M L

231C52/D 231E42 231U42 231G42 232G42 233G42

W3

THX

2446

8

MG/5

20 KM 74

IDENTIFICATION OF VEHICLES2.5 TD

II 27 = 10Q31 = 14Q

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van(2) Combi club.(3) Combi confort.

(7) Chassis cab.(8) Chassis double cab.(9) Platform cab.

RELAY 4 2 All T IDENTIFICATION O


36/344

GENERAL

(9) (10) (1

31

M L M L C M/

232H42 233H42 232H42/1 233H42/1 231F42 232

W3

THX

2446

8

MG/5

20 KM 74


2.5 TD

I) (9) Platform cab.(10) Platform double cab.

(11) Floor cab.(12) Bare chassis.

II 31 = 1

I

II

III

Type approval no.

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.



37/344

(1)

35

C/CH M/H MS LH LH (*) LS

231J42 232J42 232J42 233J42 233J42 233V42

(7) (8) (9) (10)

35L XL L M L

233K42 234K42 233G42/1 232N42 233L42 233L42

W3

THX

2446

8

MG/5

20 KM 75

IDENTIFICATION OF VEHICLES2.5 TD

II

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van(4) Minibus.(5) Public transport 16-seater.(6) Minibus 15-seater.

(7) Chassis cab.(8) Chassis double cab.(9) Platform cab.(10) Platform double cab.

(11) Floor cab.(12) Bare chassis.



38/344

GENERAL

(1) (2) (1)

27

C/CH M C C/CH M/MH M

231AH2 232AH2 231CH2/D 231BH2 232BH2 232B

(3) (7) (9) (7)

27C C M L

231CH2/D 231EH2 231UH2 231GH2 232GH2 233

W4

F28TDCR

2800

9 (*)

MG/5

20 KM 79

RELAY 4 x 2 All Types IDENTIFICATION O2.8 HDi

II 2731

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van(2) Combi club.(3) Combi confort.(7) Chassis cab.

(8) Chassis double cab.(9) Platform cab.(*) = Without lateral door(**) = (2)-(3) 10 hp



39/344

(9) (10) (11)

31

M L M L C M/MH

232HH2 233HH2 232HH2 233HH2/1 231FH12 232FH2

(12)

31XL

234GH2/2

W4

F28TDCR

2800

9

MG/5

20 KM 79

IDENTIFICATION OF VEHICLES2.8 HDi

II 31 = 14Q III (S

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (9) Platform cab.(10) Platform double cab.(11) Floor cab.(12) Chassis cab.



40/344

GENERAL

(1)

35

C/CH MH LH MS LH LH

231JH2 232JH2 233JH2 232JH2 233JH2 233J

(7)

35M L XL

232KH2 233KH2 234KH2

W4

F28TDCR

2800

9

MG/5

20 KM 77

RELAY 4 x 2 All Types IDENTIFICATION O2.8 HDi

II 35

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel or glazed van.(4) Minibus.(5) Public transport 16-seater.

(6) Minibus 15-seater.(7) Chassis cab.



41/344

(8) (9) (10) (11)

35

L M L L M/MH L/LH

233GH2/1 232KK2 233LH2 233LH2/1 232NH2 233NH2

W4F28TDCR

2800

9

MG/5

20 KM 77


2.8 HDi

I) (8) Chassis double cab.(9) Floor cab.(10) Platform double cab.

(11) Floor cab.(12) Chassis cab.

II 35 = 18Q

I

II

III

Type approval no.

Version


Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

RELAY 4 x 4 - All Types SPECIFICATIONS - IDE


42/344

GENERAL

5 Paint code

6 Vehicle identification N.

7 Bodyshell N.

8 Rear axle

RELAY 4 x 4 All Types SPECIFICATIONS IDE

Identification

1 Gearbox identification reference.

2 Manufacturers name plate

3 Engine plate.

4 Transfer box.

1 VIN N

2 Gros

3 Gros

4 Max.

5 Max.E1-P02VD



43/344

ENGINE

12

3458BCH

XU102CUXU10J2U

XUD9AUDJ5TEDDJ5XUD9UTF2.8D (*)2.8 TD (*)2.0HDi (*)

WHEELBASE

12

34

Short (2.85m)Medium (3.20m)

Long (3.70m)Superlong (4.05m)

BODY

AB

CDEFGHJKLNU

V

TR

24

FAMILY

23

Type approval no. (Example) 2 3 2 G 5 2 /

U 3 VAN 9 Q 10 QVAN 14 Q

COMBI 10 QMINIBUS 18 QCHASSIS 10 QFLOOR 10 QCHASSIS 14 QPLATFORM 14 QVAN 18 QCHASSIS 18 QPLATFORM 18 QFLOOR 18 QPLATFORM 10 Q

COMBI 14 Q

(*) = SOFIM engineNOTE : BODYWORK in A (VAN 9Q 10Q) 9Q = Van version Reduced Gross laden weightEXAMPLE : 232G52/2 = Bare chassis medium, 2.5 diesel engine, 5-speed gearbox.

SPECIFICATIONS IDENTIFICATION ( 4 x 4 ) (continued)

RELAY 4 x 4 - All Types SPECIFICATIONS - IDENTIFIC


44/344

GENERAL

WheelbaseInterior height

10 Q

1.56 m 27C/270CShort : 2.85 m 1.88 m 27CH/270CS

2.11 m 27CS/270CH

1.56 m 27M/270M

Medium : 3.20 m 1.88 m

2.11 m

1.56 mLong : 3.70 m

1.88 m

Super long : 4.05 m 1.56 m

RELAY 4 x 4 All Types SPECIFICATIONS IDENTIFICCommercial type



45/344

1 ) Letter Supplier E STA

2 ) Letter Torque J 8 X 37

F 8 X 39

3 ) and 4 ) Letters Differential 01 Limited slipidentification

02Differential

lock

(a) (b) (c)

D = Dangel D = Diesel 1 = 14Q 08

Atmospheric 5 = 18Q ge

T= Turbo diesel 7 = 10Q

E = Petrol

a = D

b = E

c = 7

d = 08

e = (R)

( ) ( )

Gearbox plate (Example)

(*)

Rear axle (Example)



46/344

(1) (2) (1)

31

C/CH MH C M MH L

231B54 232B54/1 231V54/D 232V54/D 232J54 233

(3) (4) (5)

31 35M M

232V54 232H54 232N54 233

W3

T9A

2446

8 9

ME/5

20 KE 29

DD1 04 ( R )

GENERAL

yp2.5 D

II 31 = 135 = 1

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel van.(2) Chassis confort(3) Chassis cab.

(4) Platform cab.(5) Floor cab.



47/344

(6) (1) (2) (1

27 31

C C/CH MH C MH

231C44/D 231B44 232B44/1 232V44/D 232J44

(2) (3) (4)

31M L

232V44/D 232V44 232H44 233L44

W3

THX

2446

9 8

ME/5 MG

20 KE 29 20 KM 74

DT7 04 ( R ) DT1 19 ( R )

2.5 Tdi

II 273135

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel van.(2) Combi confort(3) Chassis cab.

(4) Platform cab.(5) Floor cab.(6) Combi club

RELAY 4 x 4 All Types IDENTIFICATION


48/344

(2) (1) (3)

27 31

C C/CH MH C M

231CH4/D 231BH4 232BH4/1 231VH4/D 232

(3) (4) (5)

31M

232VH4/D 232VH4 232HH4 233

W4

F28TDCR

2800

9 (*)

MG/5

20 KM 79

GENERAL

2.8 HDi

II 273135

I

II

III

I

IIIII

Type approval no.

Type approval no.

Version

Version

Emission standard

Engine type

Capacity (cc)

Fiscal rating (hp)

Gearbox type

Gearbox ident.

I) (1) Panel van.(2) Combi club(3) Combi confort

(4) Chassis cab.(5) Platform cab.(6) Floor cab.

LUBRICATION SYSTEM


49/344

Draining method.

Oil capacities are determined by the following proced

1/ Vehicle on horizontal ground.

2/ Engine warm (oil temperature 80C).

3/ Drainage from sump + remove oil filter (time required for draining including dripping =

4/ Refit engine plug.

5/ Refit filter and refill engine with oil.

6/ Start the engine (allowing the filter to fill).

7/ Stop the engine (leave for 5 min).

IMPERATIVE : Systematically check the oil level via the o

C15 All Types CAPACITIES (in lit


50/344

GENERAL

C15

Diese

1.8D

Engine type 161A

Engine angle

Engine with filter change 4.25

Between Min. and Max. 1.5

5-speed gearbox 2

Brake circuit

Cooling system 8

Fuel tank capacity 47

(1) = Vehicle with air conditioning.

NOTE : Engine, systematically check the oil level using the oil dipstick.

CAPACITIES (in litres)


51/344

Engine type

Engine with filter change

Between Min. and Max.

5-speed gearbox

Automatic gearbox

after drainage

Hydraulic or brake circuit

Cooling systemFuel tank capacity

HDZ HFX KFX KFW LFX HFX

3.54.75

4.5 (1)

1.5 1.3

2 1.8

With ABS = 0.62 - Without ABS = 0.525

6.5 6.5-7 (1) 8 6.555

Eccap

Petrol

BERLINGO

(1) = With aircon. - NOTE : Engine, systematically check the oil level using the oil dipstick.

1.1i 1.4i 1.8i 1.1i

DISPATCH All Types CAPACITIES (in


52/344

GENERAL

Petrol

2.0i 16V 1.9 D

Engine type RFN WJZ (1) WJZ (

Engine angle 28 1630 - 1

Engine with filter change 4.25 4.5 4.5 (3)Between Min. and Max. 1.7 1.5 1.3 (3) - 1

5-speed gearbox 1.8 1.8

Automatic gearbox 8

After drainage 3

Brake circuit 0.5

Cooling system


(1)= OPR 7903#

8575 Filling with oil is by way of the oil sump.Aluminium oil sump on versions with and without aircon (Power unit angled).(2) = OPR 8576 # Filling with oil is by way of the cylinder block.Steel oil sump on versions without aircon (Power unit angled).NOTE : Engine, systematically check the oil level using the oil dipstick.

Automatic

Dispatc

CAPACITIES (in litres)


53/344

Petrol Dies

2.0i 1.9 D 1.9 TD

Engine type RFW DJY D8C DHY T9A (

Engine with filter change 4.75 - 4.5 (5) 5.25 (Without aircon) 9

Between Min. and Max. 1.5 2.95-speed gearbox 1.85 (*) 2.5

Brake circuit

Cooling system 10


(1) = NOPR # 235152 (2) = N 235153 # (3) engine DJ5T (Engine with filter change (4) = Filter cartridge capacity (litres) : 1.10. (5) With aircon.

(*) Gearbox (ML) - Gearbox (MG) = 2.5 litres.NOTE : Engine, systematically check the oil level using the oil dipstick.

Relay

ALL TYPES LUBRICANTS - TOTAL rec


54/344

GENERAL

S.A.E. Norm - Table for selection of engine oil grade

CITRONof grade STOTAL oieconomies

This oil is

- XU10 4 R- SOFIM

These eng

recognised

SAE : SocAPI : AmeACEA : Ad'AutomobE4AP006D

LUBRICANTS - TOTAL recommended oils


55/344

Selection of engine oil grades recommended for climatic conditions in c

ACEA NormsThe first letter corresponds to the type of engine concerned :

A : petrol and dual fuel petrol / LPG engines.B : diesel engines.

The figure following the first letter corresponds to the type of oil.1 : highly fluid oils, for reducing friction and lowering fuel

consumption.3 : high performance oils.

The number after that (96 or 98) corresponds to the year of creation ofthe norm.

NOTE : From 01/03/2000, all engine oils must comply with ACEA-98norms.

Example :

ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fueleconomy (complying with ACEA 98norms).

The first letter corresponS : petrol and dC : diesel engin

The second letter corresorder.Example : The normcorresponds to a higher The adding of the lettersoil which permits fuel ecEC : Energy ConservinExamples :API SJ / CF : Blended oAPI CF / EC : Oils s

economy.API SJ / CF / EC : Blend

LUBRICANTS - TOTAL recoALL TYPES


56/344

GENERAL

Recommendations.Denominations of TOTAL oils, according to country of marketing :

TOTAL ACTIVA (France only).TOTAL QUARTZ (outside France).

IMPERATIVE : From 1999 model year, to preserve engine performance, amust be lubricated with high quality oils (synthetic o

These oils must comply with the following norms :

Petrol and dual fuel petrol / LPG engines: ACEA A3-98 and API SJ.Diesel engines: ACEA B3-98 and API CF

ATTENTION : Engines fitted in CITROEN vehicles prior to 2000 model year mwith standards ACEA A1-98 / B1-98 and API S

SummaryEngine oil norms to be respected in 2001 model year.

(*) = It is essential not to use engine oils respecting these norms for the following engine-types XU10J4RS, 1580 SPI, SOFIM 2.8 D and SOFIM 2.8 TD.

Model year

2001 model year

Petrol and dual fuel petrol /LPG engines

A3-98 or A

B3-98 or BDiesel engines

Types of engine ACEA n

LUBRICANTS - TOTAL recommended oilsS A E d


57/344

S.A.E. grades

Blended oils for all engines (petrol, dual-fuel petrol / LPG

TOTAL ACTIVA 9000

TOTAL QUARTZ 90005W-40

TOTAL ACTIVA 9000 (*)

TOTAL QUARTZ 9000 (*)5W-30

TOTAL ACTIVRAC 10W-40

(*) = Blended oils for all engines, permitting fuel economy.Oils specifically for petrol and dual-fuel petrol / LPG e

TOTAL ACTIVA 7000


TOTAL QUARTZ 9000 0W-40

TOTAL ACTIVA 7000


Oils specifically for diesel engines

TOTAL ACTIVA DIESEL 7000

TOTAL QUARTZ DIESEL 7000

10W-40

TOTAL ACTIVA DIESEL 7000

TOTAL QUARTZ DIESEL 700015W-50

TOTAL ACTIVA 9000 5W-40



58/344

GENERAL

FRANCE

Metropolitan FRANCE

Metropolitan FRANCE

New CaledoniaGuadeloupeSaint-MartinLa Runion

9000 5W-40 7000MartiniqueGuyanaTahitiMauritiusMayotte

Blended oils

TOTAL ACTIVRAC

TOTAL ACTIVA

Blended oils for all engines

900 5W-409000 5W-30 (*)

7000

Oils specificadual-fuel petr

(*) = Blended oils for all engines, permitting fuel economy.

EUROPE



59/344

EUROPE

Germany7000 10W-9000 0W-4

Austria 7000 10W-Belgium

7000 10W-9000 0W-4

Bulgaria 7000 10W-

Cyprus 7000 15W-

Croatia 7000 10W-

Denmark7000 10W-9000 0W-4

Spain7000 10W-

7000 15W-Finland

7000 10W-9000 0W-4

Great Britain 7000 10W-

TOTAL QUARTZ

Blended oils for all enginesOils specifically fordual-fuel petrol / LP

9000 5W-409000 5W-30 (*)

(*) = Blended oils for all engines,permitting fuel economy

EUROPE (continued)

LUBRICANTS - TOTAL recALL TYPES


60/344

GENERAL

EUROPE (continued)

Greece70007000

Holland 7000Hungary 900

Italy 7000

Latvia 7000

Lithuania 900

Macedonia 7000

Malta70007000

Norway7000

900Poland

Portugal 7000

Slovak Republic

TOTAL QUARTZ

Blended oils for all enginesOils specificadual-fuel petr

9000 5W-409000 5W-30 (*)


EUROPE (continued)



61/344

EUROPE (continued)

7000 10W-Czech Republic

9000 0W-4

Romania 7000 10W-7000 15W-

Russia7000 10W-9000 0W-4

Slovenia 7000 10W-

Sweden7000 10W-9000 0W-4

Switzerland 7000 10W-

Turkey

7000 10W-

7000 15W-9000 0W-4

Ukraine7000 10W-9000 0W-4

TOTAL QUARTZ

Blended oils for all enginesOils specifically fordual-fuel petrol / LP

9000 5W-409000 5W-30 (*)




62/344

GENERAL

Australia

New ZealandOCEANIA 9000 5W-40 7000

Angola - Ivory Coast

Egypt - Ecuador - Gabon

Madagascar - Morocco AFRICA 9000 5W-40 7000

Dominican Republic

Senegal- Tunisia

Argentina - Brazil - Chile

Colombia - CubaSOUTH

Guatemala - Paraguay AMERICA 9000 5W-40 7000

Peru - El Salvador

Uruguay

TOTAL QUARTZ

Blended oilsfor all engines




63/344

China7000 10W-4

7000 15W-5

South Korea 7000 10W-4

Hong Kong - India

Indonesia7000 15W-5

Japan7000 10W-4

SOUTH & EAST 7000 15W-5

Malaysia ASIA9000 5W-40

7000 15W-5Singapore

Taiwan 7000 10W-4

7000 15W-5

Thaland7000 15W-5

Vietnam

TOTAL QUARTZ


Oils specifically fordual-fuel petrol / LP



64/344

GENERAL

Saudi Arabia

Bahrain

Dubai

United Arab Emirates

Israel MIDDLE9000 5W-40 7000

Jordan EAST

Kuwat

Lebanon

Qatar

Yemen

TOTAL QUARTZ




Gearbox oils


65/344

Manual gearboxEurope

Overseas France

Asia

Automatic gearbox MB3S

Automatic gearbox 4 HP 14 et 4 HP 18 All countries S

Automatic gearbox 4 HP 20 et AL4S

Transfer box and differential

C MATIC gearbox

Power-assisted steering All countries

Gearbox oils

Oils for power-assisted steering

Engine coolant



66/344

GENERAL

g

Packs

CITROEN Fluid 2 litresAll countries

Protection : - 35C 5 litres

20 litres

210 litres

Synthetic brake fluid

Packs

All countries CITROEN Fluid0.5 litre

1 litre

5litres

CITROEN hydraulic circuit fluid

Mineral fluid for hydraulic circu

TOTAL LHM PLUS Pack

All countries Norms ISO 7308-7309 1 litre

Hydraulic circuit rinsing fluid g

TOTAL HYDRAURIN

Wash / wipe fluid



67/344

CITR

Concentrate : 250 ml 9980 33 ZC

All countries Liquid ready to use : 1 litre 9980 06 ZC

Liquid ready to use : 5 litres 9980 05 ZC

Grease

All countries TOTAL MULTIS EP2

TOTAL MULTIS COMPLEX EP2

TOTAL MULTIS N4128

TOTAL PETITES MECANIQUES

(1) NLGI = National Lubrificating Grease Institute.

p

ENGINE OIL CONSUALL TYPES


68/344

GENERAL

I - Oil consumption depends on :- the engine type.- how run-in or worn it is.- the type of oil used.- the driving conditions.

II - An engine can be considered RUN-IN after:

- 3.000 miles (5.000 km) for a PETROL engine.- 6.000 miles (10,000 km) for a DIESEL engine.

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine.- 0.5 litres per 600 miles (1.000 km) for a PETROL engine.- 1 litre per 600 miles (1.000 km) for a DIESEL engine.

DO NOT WORK BELOW THESE VALUES.

IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick- This excess oil will be used up rapidly.- It will reduce the engine output and adversely affect the operation of the air ci

ENGINE SPECIFICATIONS

Engines : HDZ - HFX - KFX - HDZ/GPL - KFX


69/344

1.1i 1.4i

HDZ HFX HDZ/GPL KFX KFX/GPL

1124 1360

72/69 75/77

9.7/1 10.5/1 9.7/1 10.2/1

44.1-6200 44.1-5500 43.2-6200 55-5500

60-6200 60-5500 58.8-6200 75-5500

8.75-3800 9.4-3500 8.31-3800 11.1-3400

9.1-3800 8.65-3800 11.5-3400

6500 6500 6500

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW-rpm

Power DIN (HP-rpm)

Torque ISO or EEC (m.daN-rpm)

Torque DIN (mkg-rpm)

Max. engine speed (rpm)

g

Petrol

All Types

ENGINE

ENGINE

ENGINE SPECIFICAALL TYPES

Engines : 161 A - WJZ


70/344

EE

1.8 D 1.9 D

161 A WJZ DJY

1769 1868

80/88 82.2/88

23/1

43.5-4600 51-4600 50-4600

60.5-4600 70-4600 69.5-4600

11-2000 12.5-2500 12-2000

11.4-2000 14-2500 12.5-2000

4600 5350 4600

Engine type

Cubic capacity (cc)

Bore / Stroke

Compression ratio

Power ISO or EEC KW-rpm

Power DIN (HP-rpm)

Torque ISO or EEC (m.daN-rpm)

Torque DIN (mkg-rpm)

Max. engine speed (rpm)

Dies


71/344

ENGINE

ENGINE

COMPRESSION RATIO - ALL TYPES


72/344

EE

in bars

XUD 7 / 9

DJ525 30 20

DJ5 TED 32 35 25.5

ENGINECOMPRESSION

RATIOMINIMUM V

( - 20 %

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)

Engines : HDZ - HFX - KFX - KFW - LFX - RFN RFW


73/344

Engine type HDZ HFX KFX KFW

Maximum permissible bow 0.05

Gasket surface regrinding - 0.20

TIGHTENING TORQUES (

Crankshaft bearing screws :- Pre-tightening 2 0.2- Tightening 5.5 0.5

- Angular tightening 45 4

Connecting rod screws :

- Pre-tightening 4 0.4

- Loosening

- Tightening 3.8 0.3 2 0.2


Flywheel screw :

- Tightening 6.5 0.6 5 0.5

- Loosening

Crankshaft end pulley screw 10 1 12 1.2

Camshaft end drive screw 8 0.8 5.5 0.5

CYLINDER HEAD

ENGINE

ENGINE

SPECIAL FEATURES - TIGHTENALL TYPES

Engines : 161A - DJY - D8C - DHX WJ


74/344

EE

Engine type 161A DJY D8



TIGHTENING TOR

Crankshaft bearing screws :- Pre-tightening

- Tightening 7 0.7

- Angular tightening

Connecting rod screws :

- Pre-tightening

- Tightening 2 0

- Angular tightening 70

Flywheel screw 5 0

Pulley screw at end of crankshaft :

- Pre-tightening

- Tightening 4 0.4


Pinion screw at end of camshaft 4.5

CYLINDER H

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)

Engines : RHY - RHX - RHZ - RHW - T9A THX


75/344

Engine type RHY RHX RHZ R



TIGHTENING TORQUES (m.

Crankshaft bearing screws :

- Pre-tightening 2.5 0.2- Tightening- Angular tightening 60 6

Connecting rod screws :- Pre-tightening 2 0.2- Tightening- Angular tightening 70 7

Flywheel screw 5 0.5

Pulley screw at end of crankshaft :- Pre-tightening 4 0.4- Tightening- Angular tightening 51 5

Pinion screw at end of camshaft 4.3 0.4

Camshaft pinion fixing flange

Camshaft pinion to flange screw :- Pre-tightening- Tightening

CYLINDER HEAD

ENGINE

ENGINE

CYLINDER BERLINGO All Types

Engines : HDZ - KFX - KFW - HFX


76/344

EE

CYLINDER HEAD GASKET IDENTIFICAT

Engine type

Identification marks (Notch on cylinder head gasket) *

HDZ - KFX HFX - KFW

1234

AB

DAB

DA

BDA

BD

C

R 0 (Standard gasket) - 1 (Repair gasket)

0 (With asbestos) - 1 (Asbestos-free)

0

01

1

01

011

000

00

01

CURTY

MEILLOR

ELRING

REINZ

Material

Repairs

Suppliers

Thickness

CYLINDER HEAD (continued)

Engines : HDZ KFX - KFW HFX

C li d h d ti ht i ( d N)


77/344

Cylinder head tightening (m.daN)

X



B1DP059CB1BP10LC

HDZ KFX - KFW - HFX

ENGINE

ENGINE

CYLINDER HEADBERLINGO All Types

Engine : LFX



78/344


Engine type


LFX

* 0 = Without notch1 = One notch

B

A

0

1

C 0D 0

E 0

A 0

B 1

C 0

D 0

E 0

CURTY

MEILLOR

Suppliers


Engine : LFX

Cylinder head tightening (m daN)


79/344

- Pre-tightening 6

- Loosening OUI

- Tightening 2


LFX


X

NOTE : Oil under the hder head boUse engineRapid Plus)

B1DP05BC

ENGINE

ENGINE

DISPATCH All Types CYLINDER

Engine : RFN



80/344


Nominal dimension Repair dimension

2 - 4 - 54 - 5

R1 R2

1.10.8Gasket thickness

(mm)

Supplier MEILLOR

Marking zone"e"

Marking zone"d"

1.4

Multilayer metallic gasket


Engine : RFN

Cylinder head tightening (m daN)


81/344

X

NOTE : Oil the threads and

under the heads of the cylinder

head bolts.(Use engine oil or Molykote G

Rapid Plus).

Pre-tightening 1.5 0.1

Tightening 5 0.1

Loosening 360 2

Tightening 2 0.75Angular tightening 285 5

B1DP0.

RFN


A = Washer thickX = Length unde

ENGINE

ENGINE

CYLINDER HRELAY All Types

Engine : RFW



82/344


Engine type


RFW

A 1

B 0

C1

D 0

E 1

A 0

B 1

C 1

D 0

E 1

CURTY

MEILLOR

Suppliers

B1BP004C


Engine : RFW



83/344

X

NOTE : Oil theunder the headder head bolts(Use engine oRapid Plus).

- Pre-tightening 3.5

- Loosening NON

- Tightening 7


B1DP05BC

RFW


ENGINE

ENGINE

C15 - RELAY All Types CYLINDER


Engines : 161A - DJY - D8C- DHX


84/344

Engines Ident.

mark (A)

161A 1 notch

DJY no notch


161A - DJYIdent. Mark

(B)

Thickness(mm) 0.06

Enginetype

Piston stand-proud(mm)

0.56 0.67 1.36

0.68 0.71 1.40

0.72 0.75 1.44

0.76 0.79 1.48

0.80 0.83 1.52

161 A

DJYD8C

DHX

B1BP10SC B1BP10TC

CYLINDER HEAD

CYLINDER HEAD GASKET IDENTIFICATION

Engine : WJZ


85/344


Numberof holes

at B

Numberof holes

at A

Thickness(mm) 0.04

Enginetype

Piston stand-proud (mm)

0.51 0.55 1.26 1

0.55 0.59 1.30 2

0.59 0.63 1.34 3

0.63 0.67 1.38 4

0.67 0.71 1.42 5

WJZ

(A) = Engine identification

(B) = Thickness identification.

(*) = Use the highest piston as a reference.

2

ENGINE

ENGINE

C15 - BERLINGO - DISPATCH CYLINDER H

Engines : 161A - DJY - D8c - DHX - WJ



86/344

NOTE : Oil the threads and under theheads of the cylinder head bolts.

(Use engine oil or Molykote G Rapid Plus).


- Tightening 6 0.6



- Tightening 6 0.6


B1DP14NCB1DP13PC

D8C - DHX

161A - WJZ - DJY

161A - W

125.5

y g g ( )

161A -

B1DP05BC

CYLINDER HEAD


Engines : RHX - RHZ - RHY


87/344


No. of notchesat A

Thickness(mm)

Enginetype

Piston stand-proud (mm)

0.47 0.605 1.30 0.06 1

0.605 0.655 1.35 0.06 2

0.655 0.705 1.40 0.06 3

0.705 0.755 1.45 0.06 4

0.755 0.83 1.50 0.06 5

RHX

RHZ

RHY

ENGINE

ENGINE

BERLINGO - DISPATCH CYLINDER HEA

Engines : RHX - RHZ - RHY



88/344

NOTE : Oil the threads and under theheads of the cylinder head bolts.

(Use engine oil or Molykote G Rapid Plus).


- Tightening 6 0.6


B1DP15EC

RHX - RHZ - RHY


B1DP05BC

CYLINDER HEAD

Engines : T9A - THX

Cylinder head gasket identification Cylinder head tightening (m.daN)


89/344

Engine type

T9A 1.6

THX

NOTE : Single cylinder head gasket

1.4

Thickness (mm) T9A - THX

- Pre-tightening the bolts :

Angular tightening

B1DP03XC

- 1 14 (Vis 12) 5 0.5

- 15 22 (Vis 10) 3.5 0.3

T9A

120 5 150 5

THX

ENGINE

ENGINE

Tools

ALL TYPES BELT TENSION/SEEM UNITS CORR

! 4099-T (C.TRONIC.105)!


90/344

B1EP135D

AUXILIARY EQUIPMENT DRIVE BELT

Engines : All Types Petrol and Diesel


91/344

TOOLS

- Belt tension measuring instrument : 4122-T.

ESSENTIAL

- Before refitting the auxiliary equipment drive belt, check that :

1) The roller(s) rotate freely (no play or stiffness).

2) The belt is correctly engaged in the grooves of the various pulleys.

ENGINE

ENGINE

AUXILIARY EQUIPMENT DRIVE B

Engines : HDZ - HFX - KFX - KFW

Alternator


92/344

[1] Belt tension measurer : 4122-T- New belt- 87 SEEM units.

- Reused belt

- 61 SEEM units.

- New belt- 100 SEEM units.

- Reused belt

- 75 SEEM units.

Power steering

B1BP121C

B1BP122C


Without air conditioni

Engine : LFX


93/344

- (3) and (5) Roller support fixing screws.

- (6) tensioning screw.

- Tighten the belt, by loosening the screw (6) to : In SEEM units.

- Tighten the screws (3) and (5).

- Rotate the crankshaft by 4 turns (direction of rotation).

- Loosen the screws (3) and (5).

- Tension the belt, by slackening the screws (6) to : In SEEM units

- Tighten the screws (3) and (5) to 2 m.daN

100 10

LFX

115 5

LFX

ENGINE

ENGINE


With air

Engine : LFX


94/344

- Fit the drive belt.

- The tensioner roller (1).

- Tighten the screws (3) to 2 m.daN.

- Turn the tensioner roller (1) using the tool (9.52

the tool or locking peg ( 4 mm ) at (4).

- Slowly release the tensioner roller (1) so that t

B1BP1HJC

AUXILIARY EQUIPMENT DRIVE BELTEngine : RFNWithout air conditioning

Tools


95/344

Tools

[1] Pliers for removing plastic pegs 7504-T

Remove the belt.- Detension the belt (3) by turning the screw (2) of the tensioner roll

(anti-clockwise).- The screw (2) (WARNING: not left hand screw).- Remove the belt (3), while keeping the tensioner roller (1) tight.

Refit the belt.- Refit the belt (3), while keeping the tensioner roller (1) tight.- Release the tensioner roller (1).

B1BP23PC B1BP23QC B1BP


96/344

AUXILIARY EQUIPMENT DRIVE BELTEngine : RFW (continued)

Alternator belt (with air con


97/344

- NOTE : If the vehicle is equipped with power steering, remove the

TENSIONING THE BE

- Tension the belt (5) using the screw (6).- Fit the tool [1].- Pre-tension to : 120 10 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 4 turns.- Fit the tool [1].- Loosen the screws (3) and (4).- Adjust the tension, using screw (6), to : 140 5 SEEM units.- Remove the tool [1].- Tighten the screws (3) and (4) to 2 m.daN.- Run the engine for 10 min.- Check the tension of the belt (5).- The nominal value must not be less than 100 SEEM units.

- If this is not the case, restart the tensioning operation.

B1BP1LFC B1BP04AC

ENGINE

ENGINE

AUXILIARY EQUIPMENT DRIVE BEngine : RFW (continued)

Power-assisted ste


98/344

[1] Belt tension measuring instrument : 4122-TREMOVING TH

- To make it easier to move the pump, unclamp the hydraulic

- Slacken the articulating screws of the pump.

- Slacken the nut (2) to release the belt (1).

TENSIONING TH- Tension the belt by turning the nut (2).- Fit the tool [1].- Pre-tension to : 70 5 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 3 turns.- Fit the tool [1].- Adjust the tension by turning the nut (2) to : 75 5 SEEM u- Remove the tool [1].- Tighten the screws (3) and the pump articulating screws to- Run the engine for 10 min.

- Check the belt tension (1).- The nominal value must not be less than 70 SEEM units.- If this is not the case, restart the tensioning operation

AUXILIARY EQUIPMENT DRIVE BELTEngines : 161A - DJY

Alternator


99/344

[1] Belt tension measuring tool : 4122-T

- Fit the tool [2] at (B).- Tighten the tensioning screw (3) toobtain a value of :

112 10 SEEM units.


- Fit the tool [2] at (C).- Tighten the tensioning screw (5) toobtain a value of :

115 10 SEEM units.

- Tighten the screw (4) to 2 m.daN.

Power steering

ENGINE

ENGINE


Without air co

Engines : DHX


100/344

- Tension the belt by loosening the screw (4) to obtain 115 10 SEEM units


- Rotate the crankshaft by 4 turns (direction of rotation


- Tension the belt to :115 10 SEEM units (If necessary).

- Tighten the screws (1) and (3) to 2 m.daN.

AUXILIARY EQUIPMENT DRIVE BELTEngines : DHX

With air conditioning


101/344

[1] Peg 7019-T

- Loosen the screws (1).

- Tighten or loosen the screws (2) until the holes a and b are s

- Place the peg [1] : (in hole a).

- Tighten the screw (2) to its stop.

- Loosen the screw (2), so as to remove the peg [1].

- Tighten the screws (1) to 2 m.daN.

B1BP1HGC B1BP1HHC


102/344

AUXILIARY EQUIPMENT DRIVE BELTEngines : DJY - D8C - DHX (continued)

Alternator (with air condit


103/344

- NOTE : If the vehicle is equipped with a power steering pump, rem

TENSIONING THE BE

- Tension the belt (5) by turning the screw (6).- Fit the tool [1].- Carry out a pretensioning of : 120 10 SEEM units.- Remove the tool [1].- Rotate the crankshaft 4 turns.- Fit the tool [1].- Slacken the screws (3) and (4).- Adjust tension using screw (6) to : 140 5 SEEM units.- Remove the tool [1].- Tighten screws (3) and (4) to 2 m.daN.- Run the engine for 10 min.- Check the tension of the belt (5).- Nominal value should not be less 100 SEEM units.

- If this is not the case, restart the tensioning operation.

B1BP1LFC B1BP04AC

ENGINE

ENGINE

AUXILIARY EQUIPMENT DRIVE BEngines : DJY - D8C - DHX (continued

Belt for power-assisted


104/344

REMOVING TH

- To make it easier to move the pump, unclamp the hydraulic- Slacken the articulating screws of the pump.- Slacken the nut (2) to release the belt (1).

TENSIONING TH

- Tension the belt by turning the nut (2).- Fit the tool [1].- Pre-tension to : 70 10 SEEM units.- Remove the tool [1]- Rotate the crankshaft by 3 turns.- Fit the tool [1].- Adjust the tension by turning the nut (2) to : 75 5 SEEM u- Remove the tool [1].- Tighten the screws (3) and the pump articulating screws to- Run the engine for 10 min.- Fit the tool [1].

- Check the tension of the belt (1).- The value must not be less than 70 SEEM units- If this is not the case, restart the tensioning operation


Without power-assisted steering

Engines : WJZ


105/344

Tools :

[1] Belt tension measuring instrument : 4122-T.

Removal.

- Loosen the screws (2).- Tighten the screw (1) until it is against its stop.- Remove the belt.

Refitting.- Refit the belt.- Fit the tool [1] at "d".- Tighten the screw (1) to obtain : 115 10 SEEM units.- Tighten the screws (2) to 2 m.daN.- Remove the tool [1].

B1BP1SDC

E

NGINE

E

NGINE

Without power-assisted steering/with air con

Engines : WJZAUXILIARY EQUIPMENT DRIVE BE


106/344

Tools :

[1] Belt tension measuring instrument 4122-T.

Removal.

- Loosen the screws (1).- Tighten the screw (2) until it is against its stop.- Remove the belt.

Refitting.- Refit the belt.- Fit the tool [1] at "e".- Tighten the screw (2) to obtain : 115 10 SEEM uni- Tighten the screws (1) to 2 m.daN.- Remove the tool [1].

B1BP1SFC


Power-assisted stee

Engines : WJZ


107/344

[1] Belt tension measuring instrumen

Removal.

WARNING : If the belt is to be reLoosen :- the screw (1).- the nut (2).

NOTE : The tensioner arm (3) must b

- Remove the belt.

B1BP1SHD

E

NGINE

E

NGINE

AUXILIARY EQUIPMENT DRIVE BE

Power-assisted stee

Engines : WJZ


108/344

Refitting.- Refit the belt.- Place the tool [1] on belt at "fWARNING : Position tool [1],- tighten the nut (2) to obtain a Reused belt :

Keep the value taken at removNew belt :Tension should be 110 SEEM - Tighten the screw (1) to 9.5 m- Check belt tension (tool [1] ).Tension should be 144 3 SE- Remove the tool [1].- Start the engine and run it for- Stop the engine.- Place the tool [1] on the belt - Tension should be 130 4 S- Remove the tool [1].

B1BP1SJD


Power-assisted steering

Tools

Engines : WJZ


109/344

Tools

[1] Dynamic tensioner peg (-) 0188[2] Belt tension measuring instrument 4122-T.

Removal.- Peg the dynamic tensioner (1) at "a", using tool

- Loosen the screw (2) of the roller (3).- Turn the roller (3) backwards.- Remove the belt.NOTE : If it can not be pegged at "a" :- Loosen the screw (2) of the roller (3).- Using a 7 mm square drive, turn the roller (3) a- Peg the tensioner (1) at "a", using tool [1].NOTE : If the belt is broken :- Support the engine using a jack (insert a woode- Remove the right engine support.- Using a square drive at (b) turn the tool (3) in th

pegged at "a" using the tool [1].

B1BP1SKC

E

NGINE

E

NGINE

AUXILIARY EQUIPMENT DRIVE BE

Power-assisted steering

Engines : WJZ


110/344

Refitting.

- Refit the belt.

- Using a 7 mm square drive at "b", turn thebecomes free.

- Tighten the screw (2).

- Remove the tool [1].

B1BP1SLC

AUXILIARY EQUIPMENT DRIVE BELTEngines : RHX - RHY - RHZ

Without


111/344

[1] Belt tension adjusting square[2] 4 mm peg[3] 2 mm peg[4] Dynamic tensioner compression le

Remove

RE-UWARNING : Mark the direction the b

the same belt.- Compress the tensioner roller (2) by

tool [4].- Keep the tensioner roller (2) compre

NO RE

- Compress the tensioner roller (2) by tool [4].

- Peg using tool [2], at b.

- Hold the tensioner roller (2) compres- Loosen the screw (1).

E

NGINE

E

NGINE Engines : RHX - RHY - RHZ

Without

Refit.



112/344

- Compress the tensioner rollertool [4].

- Refit the belt.

WARNING : Respect the direc

Remove the tool [4].

Refit the belt.- Turn the eccentric roller (3), to

at b .- Hold the eccentric roller (3), to- Remove the tool [2].- Rotate the crankshaft 4 times- Check that it is possible to pe

- If not possible to peg, restart t

AUXILIARY EQUIPMENT DRIVE BELTEngines : RHX - RHY - RHZ

With a


113/344

[1] Belt tension adjusting square[2] 4 mm peg[3] 2 mm peg[4] Dynamic tensioner compression le

Remove

RE-UWARNING : Mark the direction the be- Compress the tensioner roller (7) by

tool [4].- Hold the tensioner roller (7) compres

NO RE- Compress the tensioner roller (7) by

tool [4].- Peg using tool [2], at d .- Loosen the screw (6)- Bring the eccentric roller (5) towards

- Tighten the screw (6) by hand.- Remove the belt.

E

NGINE

E

NGINE

AUXILIARY EQUIPMENT DRIVE BEngines : RHX - RHY - RHZ

With a

Refit.


114/344

- Compress the tensioner rolletool [4].

- Refit the belt.

WARNING : Respect the direRemove the tool [4].

- Refit the belt.- Turn the eccentric roller (5), t

at d .- Hold the eccentric roller (5), t- Remove the tool [2].- Rotate the crankshaft 4 times- Check that it is possible to pe

- If not possible to peg, restart


REMOVING THE BELT

Engines : T9A - THX

Belt for alternator and power-assisted steering pump


115/344

REMOVING THE BELT

- Slacken the screws (1) and the lock nut (2).- Turn the screw (3) (direction of tightening).- Remove the belt.

REFITTING THE BELT

- Pre-tighten the screws (1) of the tensioner to 1 m.daN.

TENSIONING THE BELT- Fit the tool [1].- Turn the screw (3) (direction of loosening) to tension the belt.

- The tension value should be 138 12 SEEM units.- Remove the tool [1].- Rotate the crankshaft by 3 turns (direction of rotation).- Fit the tool [1].- Adjust the tension using the screw (3) to 138 12 SEEM units.- Remove the tool [1].

B1BP1WCC B1BP03PC

E

NGINE

E

NGINE

AUXILIARY EQUIPMENT DRIVE BEEngines : T9A - THX (continued)

Water pump

Tension the belt (3) by turning the screw (2)


116/344

- Tension the belt (3) by turning the screw (2).- Fit the tool [1].- Pre-tension to :

New belt : 62 SEEM units.Reused belt : 41 SEEM units.

- Remove the tool [1].- Rotate the crankshaft by 10 turns (direction of rotation).- Fit the tool [1].- Adjust the tension to obtain :

New belt : 62 SEEM units.Reused belt : 41 SEEM units.


B1BP04DC B1BP04EC

CHECKING AND SETTING THE VALVE TIMING

1.1i

H K

1.4i 1.8i2.0i16V

2.0i 1.8D 1.9D1.9TD


117/344

Engine type

C15

BERLINGO

DISPATCH

RELAY

See pages :

HDZ

DZ/GPL

HFX

KFX

FX/GPL

KFW

LFX

RFN

RFW

161A

DJY

D8C

DHX

X X

X X X X X X X

X

X X X X

117to

118

121to

125

119to

120126 127114 to 116

E

NGINE

E

NGINE

TOOLS- [1] Flywheel locating peg : 4507-T.A- [2] Camshaft pulley locating peg : 4507-T B

CHECKING AND SETTING THE VALVE

Engines : HDZ - HFX - KFX KFW


118/344

[2] Camshaft pulley locating peg : 4507-T.B- [3] Square drive : 4507-T.J- [4] Belt tension measuring instrument : 4122-T- [5] Rocker plate : 4533-T.Z

CHECKING THE VALVE TIMING

- Peg the flywheel using the tool [1]- Peg the camshaft pulley [2].

SETTING THE VALVE TIMING

NOTE : Remove the spark plugs to ease the crankshaft rotat- Rotate the engine with the crankshaft screw (1).- Peg the camshaft pinion.- Peg the flywheel.- Loosen the nut (2).- Completely slacken the belt by turning the tensioner roller (- Remove the belt.

ESSENTIAL : Check that the tensioner roller rotates free

B1EP067C B1EP066C

CHECKING AND SETTING THE VALVE TIMEngines : HDZ - HFX - KFX - KFW (continued)

REFITTING THE TIMING NOTE : Check that the pegs [1] and [2] are in place.


119/344

p g [ ] [ ] pWARNING : Ensure the belt is fitted in the right direction : Thetion of rotation.Fit :-The timing belt, with the belt strip b well tightened, in the followiCrankshaft pinion, camshaft pulley, water pump pulley, tensioner ro

-The tool [5] (Ensure it is fitted in the right direction in relation to th-Bring the tensioner roller into contact with the belt.-Tighten the nut (2).

PRE-TENSIONING THE TIMIN-Fit the tool [4] on the tightened belt strip b.-Loosen the nut (2).-Turn the roller (3) in an anti-clockwise direction using a square driv

44 SEEM units.-Tighten the nut (2) to 2.2 m.daN.-Remove the tools [1], [2] and [4].-Rotate the crankshaft by 4 turns in the normal direction of rotation

ESSENTIAL : Never turn the crankshaft backwards.

ENGINE

ENGINE


Engines : HDZ - HFX - KFX - KFW (contin

PRE-TENSIONING THE TIMING BELT (co


120/344

(

-Ensure the timing is correctly set by refitting the pegs [1] and [2].-Remove the cylinder head cover.-Fit the tool [5] (Ensure it is fitted in the right direction in relation to the timing).

ADJUSTING THE BELT FITTING TENS

-Fit the tool [4] to the tightened belt strip.-Loosen the nut (2).-Slacken the belt (not excessively).-Tighten the timing belt to obtain :

29 and 33 SEEM units.-Tighten the nut (2) to 2.2 m.daN.-Remove the tools [1], [2], [4] and [5].

CHECKING THE BELT TENSION

-Rotate the crankshaft by 2 turns in the normal direction of rotation.-Check that the following components can still be pegged :-Flywheel.

-Camshaft.ESSENTIAL : If the components can not be pegged, repeat the belt tensioning proce

CHECKING AND SETTING THE VALVE TIM

Engine : L

TOOLS

B l i i i 4099 T 41


121/344

- Belt tension measuring instrument : 4099-T ou 41- Camshaft pulley locating peg : 7004-T.G.- Crankshaft locating peg : 7014-T.N.- Square drive : 7017-T.W.

CHECKIN- Remove the protective covers.

- Peg the camshaft pulley at a, using tool 7004-T.G- Peg the crankshaft at b, using tool 7014-T.N.

SETTING THE VAL- Check that the pegs can be engaged correctly at a- Fit the belt in the following order : camshaft pulley, cr

pinion, tensioner roller.- Peg the camshaft pulley at a and the crankshaft a- Remove the peg at b only.- Bring the tensioner roller (2) into contact with the bel

B1EP07SC

ENGINE

ENGINE


Engine : L

SETTING TH

- Fit the tension measuring tool to the middle o


122/344

Fit the tension measuring tool to the middle o- Turn the tensioner roller (2) (anti-clockwise d

to obtain the value 30 2 SEEM units.- Tighten the screw (1) to 2 m.daN.- Remove the tools.- Rotate the crankshaft by two turns (do not tu

- Check the setting by positioning the pegs at- Remove the pegs.

CHECKING

- Rotate the crankshaft by two turns (do not tu- Peg the camshaft pulley at a.- Fit the tension measuring tool on the belt stri- The tension measurement should be 44 2

(If the measurement is not correct, repeat the- Remove

B1EP07RC

CHECKING AND SETTING THE VALVE TIMI

Engine : RFW

TOOLS

[1] Camshaft pulley locating peg : 7004 - T.G[2] - Flywheel peg : 7014 - TN


123/344

B1EP01TC B1BP1WHC

[2] Flywheel peg : 7014 T.N [3] - Timing belt tensioning key : 7017 - T.W[4] - Toothed sector for locking the flywheel : 6012 - T [5] - Belt tension measuring instrument : 4122 T

CHECKING- Turn the engine by the crankshaft screw (do not turn backwards)- Peg the crankshaft using the tool [2].- If the timing is not correct, repeat the operation.

SETTING THE VALVE TIMING- Peg the crankshaft using tool [2], and the camshaft pulley using t- Lock the flywheel with the tool [4].ESSENTIAL : Remove the tools [1] and [2] when tightening the- Remove the screws (1) and the pulley.- Remove the tool [4].- Check that the camshaft pulley and the crankshaft pinion are corr- Loosen the tensioner roller screw.

- Remove the belt.

ENGINE

ENGINE

CHECKING AND SETTING THE VALVE TIMING

SETTING THE VALV

Belt fitting dire- Arrows in the direction of rotation.

Engine : RFW (c


124/344

- Paint marks opposite pinion marks.

- Fit the belt on the : camshaft pulley, crankshaft pinion, water

NOTE : Ensure that the belt is correctly positioned in the groo

TENSIONING TH

- Bring the tensioner roller into contact with the belt.- Fit the tool [5].- Tension the roller to 16 2 SEEM units using the tool [3].- Tighten the screw (2) to 2 m.daN.- Remove the tool [1] and fit the crankshaft pulley, without tigh

- Rotate the crankshaft by 2 turns (direction of rotation).

- Check the pegging of the camshaft/crankshaft.

- Rotate the crankshaft by 2 turns (do not turn backwards).

- Peg the camshaft pulley using the tool [1].

- Fit the tool [5].

ESSENTIAL : The tension value should be : 40 4 SEEM

- If the value is outside these limits, restart the operation.- Remove the tools.

TOOLS

[1] Camshaft setting pegs : (-).0189.A[2] Crankshaft setting peg : (-).0189.B


Engine : RFN


125/344

[ ] g p g ( )[3] Belt locking pin : (-).0189.K Tool [4] Angular tightening adaptor : 4069-T.[5] Hub immobilising tool : 6310-T

CHECKING THE VALVE T

- Turn the engine by the crankshaft pinion screw (3) to bring it to pe- Peg the crankshaft, using tool [2].- Peg the camshaft pulleys, using tools [1].

NOTE : The pegs [1] must go in without effort.

MO

TEUR

CHECKING THE VALVE TIM


Engine : RFN


126/344

WARNING : If the pegs do not engage without effort, restabelow).

SETTING THE VAL

Remove

- Remove the screws (2), the pulley (1), upper valve cover (4- Turn the engine by the screw (13) of the pinion (12) to bring- Peg the pulleys (8) and (9) using tools [1].- Peg the pinion (12) using tool [2].- Loosen the screw (7) of the tensioner roller (6).- Turn the tensioner roller (6) (clockwise).- Remove the timing belt (10).

REFIT (continued)-Refit the belt (10) on the pinion (12).-Hold the belt (10) with tool [3].Position the belt (10) in the following order :


Engine : RFN


127/344

-Position the belt (10) in the following order :-The guide roller (11), the inlet camshaft pinion (9), the exhaust camsioner roller (6).NOTE : Make sure that the belt (10) is as flush as possilble with the-Remove the tools [3] and [1].

TIMING BELT TENSIOAdjusting the tension-Turn the roller (6) in the direction of the arrow b; using an Allen k-Position the index c in its maximum setting at d.IMPERATIVE : The index c must stand proud of the notch freplace the tensioner roller (6) or the timing belt and the tensioBring the index c to its adjusting position f by turning the tensioWARNING: The index c must not stand proud of the notch f : iration.IMPERATIVE : The tensioner roller (6) must not turn while its fixmence the adjusting operation.

MO

TEUR

Adjusting the tension (continued).-Tighten the screw (7) of the the tensioner roller (6) to 2.1 0IMPERATIVE : The hexagonal drive of the tensioner rollerhead gasket g If not replace the tensioner roller (6) or


Engine : RFN


128/344

head gasket g. If not, replace the tensioner roller (6) or

Refit (continued).- Remove the tools [1] et [2].- Turn the crankshaft 10 times in the normal direction of rotatIMPERATIVE : No pressure or outside action must be bro

- Peg the inlet camshaft pulley, using the tool [1].

CHECKSTIMING BELT TE

IMPERATIVE : Check the position of the index c, it shindex c is not correct, restart the adjustment of its pos

Positioning of the crankshaft- Fit tool [2].- As long as it is possible to fit tool [2], continue with the refit IMPERATIVE : If it is not possible to fit tool [2], reposition

CHECKS (continued).

R iti i th fl


Engine : RFN


129/344

Repositioning the flange- Immobilise the crankshaft using tool [5].- Loosen the screw (13).- Release the pinion (12) of the crankshaft.- Bring the flange (14) to the pegging position; using tool [5].

- Fit the tool [2].- Immobilise the crankshaft using tool [5].- Tighten screw (13) to 4 0.4 m.daN, then angular tighten 53 4- Remove tools [1], [2] and [5].

Refit :- The lower valve cover (3).- The upper valve cover (4)- The crankshaft pulley b- The screws (2).- Pretighten the screws (2) to 1.5 m.daN.- Tighten the screws (2) to 2.1 0.5 m.daN

MO

TEUR


Engine : 161 A

T- Flywheel locating peg- Injection pump and camshaft locating peg


130/344

CH- Peg the crankshaft.- Peg the camshaft at a and the injection pum

SETTING TH- Peg the crankshaft.- Peg the camshaft at a and the injection pum- Fit the belt in the following order :Crankshaft pinion, guide roller (3), injection pumtensioner roller (5), water pump (4).- Remove the pegs.- Free the tensioner roller (5) (nut (6) and screw- Rotate the crankshaft by 2 turns. Do not turn - Loosen the tensioner roller (5), allow the tensio- Retighten the screw (7) and the nut (6). Tighten- Check the setting.NOTE : The injection pump is removed without c

(immobilise the injection pump pulley usB1EP09KC B1EP080C


Engine : WJZ

TOOLS


131/344

- [1] HM screw : (-) 0 188 E- [2] Locating peg 6 mm : (-) 0 188 H- [3] Flywheel locating peg : (-) 0 188 D (or 7- [4] Toothed sector for locking the flywheel : (-) 0 188 F- [5] Belt retaining clip : (-) 0 188 K

- [6] Square drive for adjusting the tension : (-) 0 188 J- [7] Belt tension measuring instrument : 4122-T- [8] Toothed sector for locking the flywheel : 6016-T

CHECKING THE VALVE TI

- Peg the flywheel using tool [3].- Visually check that the offset between the camshaft and injection

pegging holes does not exceed 1 mm.

B1CP045C

MO

TEUR


Engine : WJZ

Setting the valve timing

Peg :


132/344

- The camshaft hub (1), using tool [1].- The injection pump pinion (2), using tool [2].- The flywheel, using tool [3].

- Lock the flywheel, using tool [4].

- Refit the screw (3) (without tightening it). (Coat the threads- Tighten the screw (3) to 4 m.daN and finish by carrying ou

tightening of 60.- Remove the tool [4].- Retighten screws (4) and (5) by hand.- Turn the pinions (6) and (2) so that they are at the end of t

(Clockwise direction).- Place the belt on the crankshaft and hold in place using too- Fit the belt in the following order:

Roller (7), pinion (2), pinion (6), pump (8) and roller (9).

B1EP131CB1EP130C


Engine : WJZ

Setting the valve timing (continued)


133/344

NOTE : If necessary, slightly turn pinions (6) and (2) in an anti-clockin order to fit the belt.The angular movement of the belt in relation to the pinions mu1/2 tooth.

- Fit the tool [7] to the belt strap at "a".- Turn the roller (9) (anti-clockwise) using tool [6], to obtain:

106 2 SEEM units.- Check that pinions (6) and (2) are not at the end of their stops.Otherwise, repeat the belt fitting procedure from the beginnin

Tighten:- The roller (9) to 4.5 m.daN.- The screws (4) and (5) to 2.5 m.daN.- Remove the tools [7], [5], [1], [2] and [3].

B1EP134C B1CB1EP133C

MO

TEUR


Engine : WJZ


Rotate the crankshaft by 8 turns (direction of rotation).


134/344

Peg :- The hub (1), using tool [1].- The pinion (2), using tool [2]- The flywheel, using the tool [3].

Loosen :- The screws (4) and (5).- The roller (9).- Retighten screws (4) and (5) by hand.- Fit the tool [7] to the belt strap at "a".- Turn the roller (9) (anti-clockwise direction) using tool [6], t

42 2 SEEM units.

B1EP134CB1EP133C


Engine : WJZ


Tighten :Th ll (9) 2 1 d N


135/344

- The roller (9) to 2.1 m.daN.- The screws (4) and (5) to 2.3 m.daN.

- Remove the tool [7].- Fit the tool [7] to the belt strap at "a".

- The tensioning value should be between 42 2 SEEM units.

ESSENTIAL : If the value obtained is outside the set limits, rsioning operation.

- Remove the tools [7], [5], [1], [2] and [3].- Rotate the crankshaft by 2 turns (direction of rotation).

- Check the valve timing.

B1EP134CB1EP133C B1


136/344


Engine : RH

Setting thePeg :

The engine fl heel tool [3]


137/344

- The engine flywheel, tool [3].- The camshaft, tool [5].Loosen :- The three screws (9).- The screw (7) of the tensioner roller (6).

Remove the timing belt.

Checks.

IMPERATIVE : Just before refitt

Check that :

- The rollers (6), (11) and the water pump (1- There are no traces of oil (on camshaft or c

MO

TEUR


Engine : RHY - RHX - RHZ

Setting the valve timing (continued).

- Retighten screws (9) by hand.- Turn the pinion (12) (clockwise) to the bottom

the buttonhole


138/344

the buttonhole.- Refit the belt on the crankshaft, in the follow

order, using the tool [4] to keep the belt tight a

- Guide roller (11).

- Fuel high pressure pump pinion (13).- Camshaft pinion (12).- Water pump pinion (10).- Tensioner roller (6).

NOTE : If needed, slightly turn the pinion (12)clockwise (not by more than one tooth).


B1EP13FCB1EP13ED

Setting the

- Position tool [1] on the belt at- Turn the roller (6) (anti-clockw


Engin


139/344

- Tighten screw (7) of the roller- Remove one screw (9) from th

(to check that the screws are n

- Tighten the screws (9) to 2 m - Remove tools [1], [2], [3] and- Rotate the crankshaft 8 times- Fit the tool [3].- Loosen screws (9).- Fit tool [5].- Loosen screw (7) (to free the r- Fit tool [1].- Turn the roller (6) (anti-clockw

MO

TEUR


Calage de la distr

Tighten :- The screw (7) of the ro- The screw (9) to 2 m d


140/344

- The screw (9) to 2.m.d- Remove the tool [1].- Refit the tool [1].- Tension value should b

IMPERATIVE :

- Remove tools [1], [3] a- Rotate the crankshaft 2- Fit the tool [3].

WARNING : Should the offset between tnot more than 1 mmIn the case of an inc


CHECKING AND SETTING THE RELAY 2.5 D

TOOLS

[5] Belt tension measuring instrument : 4122 - T

Engine : T9A


141/344

[1] Flywheel peg : 7014 - T.J

[2] Camshaft pulley locating peg : 5711 - T.A

[3] Injection pump pulley locating peg : 5711 - T.B

[4] Tensioning lever : 5711 - T.E

CHECKS

- Peg the flywheel using tool [1], at (a) at the front or (b) at the bac

- Visually check the pegging of the :

The camshaft pulley.

The injection pump pulley.

- If the results of the visual check are not satisfactory, set the valve

9

MOTEUR


SETTING THE VALV

Removing the

Turn the crankshaft (direction of rotation)

Engine : T9A (c


142/344

- Turn the crankshaft (direction of rotation).

- Peg the flywheel.

- Peg :

The camshaft pulley using tool [2].

The injection pump pulley using tool [3].

NOTE : BOSCH injection pump, 9.5 mm peg - LUCAS DIE

- Loosen :

The screws (1) using tool 6016 - T.

The screws (2).

- Tighten the screws (1) and (2) by hand and slacken by 1/6

- Slacken the nut (3).

- Remove the belt.

CHECKING AND SETTING THE VALVE TIMIN

SETTING THE VALVE TIM

Refitting the belt- Refit in the following order : crankshaft pinion (hold), guide roller, i

(t th ll th t th l t t th b lt)

Engine : T9A (continu


143/344

(turn the pulley on the tooth closest to the belt).

Tensioning the belt

- Fit the tool [5].- Pre-adjust the tension using the tool [4] (tension adjusting spanne

- Adjust the tension to : New belt to 107 SEEM units. Reused belt to 80 SEEM units- Tighten the tensioner roller to 4.5 m.daN.

Checking the fitting pre-te

- Correct the tension, if necessary, using the tool [5].- Tighten the screws (1) and (2) pre-tighten to 1 m.daN, tighten to 2- Remove all the tools.- Rotate the engine through 10 turns.- Peg the flywheel using the tool [1] (direction of rotation).


MOTEUR


SETTING THE VAL

Checking the fitting

- Tighten the screws (1) and (2) by hand, then loosen by 1/6- Slacken the belt completely (using the tensioner roller).

Engine : T9A (co


144/344

p y ( g )- Peg : the camshaft pulley using the tool [2] and the injectio- Fit the tool [5].- Adjust the belt tension using the tool [4] to :

New belt to 58 SEEM units

Reused belt to 51 SEEM units- Tighten the roller to 4.5 m.daN.

Checking the fittin

- Remove the tool [5] (make any necessary correction).- Tighten the screws (1) and (2) pre-tighten to 1 m.daN, tight- Remove the tools.- Rotate the engine through 2 turns.

Checks

- Peg the flywheel using the tool [1].- Visually check the pegging of the camshaft and injection pu- If incorrect, repeat the setting operation.- Remove the tools.


TOOLS

[1] Flywheel peg : 7014-T[2] Camshaft pulley locating peg : 5711-T[3] Injection pump pulley locating peg 9.5 mm : 5711-T

Engine : THX


145/344

[4] Pinion locking tool : 6016-T[5] Belt tension measuring instrument : 4122-T[6] Tensioning lever : 5711-T[7] Tensioning locking pin : (-) 017[8] Belt retai

(2001) berlingo c15 jumper jumpy

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